Fine-Tune Your Safety Stock Levels with SAP SCM Supply Network Planning Advanced Safety Stock Planning

Claus Bosch Solution Management SCM SAP AG

Advanced Safety Stock Planning

Inventory Management and Inventory Optimization Safety Stock Planning in SAP SCM SNP

Inventory Optimization

What is Inventory Management?

Inventory management
Is the process of ensuring the availability of products through inventory Handles all functions related to the tracking and management of material, including the monitoring of material moved into and out of stockroom locations, and the reconciling of the inventory balances Consists of two broad areas: Inventory accounting, which is the administrative aspect Inventory planning and control, which consists of planning procedures and techniques that lead to inventory order action Controls stock levels within the physical distribution function to balance the need for product availability against the need for minimizing stock holding and handling costs

The objective
Is to get the right inventory, in the right place, at the right time, in the right quantity, in the right form, and at the right cost

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What is Inventory Optimization?

Inventory optimization
Is a set of products and services to help customers identify and evaluate supply chain inventory strategies from either a strategic or a tactical level

The objective
Is to determine inventory strategies and inventory influencing parameters throughout the supply chain While minimizing the inventory buffer needed to achieve a predefined target service level Or, maximizing the service level with a predefined inventory buffer

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Inventory and Service Level Trade-Off

Inventory vs. Service Level Trade-Off

Service level improvement is typically accompanied by dramatically increasing inventory

Optimized inventory locations and levels execution efficiency

Material Inventory

Reduced Inventory

Service Level

Better Service

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Strategies for Improving Trade-Off Balance

Reduce potential for a stock-out situation

Reduce lead times Improve supply chain execution Improve order fill Reduce lot sizes

Utilize existing inventory in the best way possible

Reduce obsolescence and obsolete inventory Reduce duplicate materials Manage interchangeabilities

Improve responsiveness
Through better process integration Through better system integration (less time lost due to data integration between different systems)

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Strategies for Improving Trade-Off Balance (cont.)

Understand the need for inventory buffers
More accurate knowledge of actual lead times and variability Better and more accurate demand visibility Better inventory visibility through network driven approach

Work/act optimally within predefined inventory strategies

Calculate safety stocks based on current demand information

Define inventory strategies

Determine the optimal inventory strategies Determine inventory stocking locations in the network

Only the above highlighted strategies are covered in this presentation

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Advanced Safety Stock Planning

Inventory Management and Inventory Optimization

Safety Stock Planning in SAP SCM SNP

Inventory Optimization

Safety Stock Planning in SAP SCM SNP

Safety stock planning in Supply Network Planning (SNP) deals with the regular planning tasks of managing short-term and mid-term inventory levels
Objectives Define key parameters for operative planning (safety stock) Manage inventory levels on an operational basis to cope with planning uncertainties in demand and supply Design of the supply chain and key parameters are predefined Supplier relationships Lead times Demand (forecast demand, customer demand, dependent demand, etc.) Stocking strategies for each location

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Methods to Protect Against Uncertainty

Uncertainty of supply

Uncertainty of demand

Overestimate customer demand Underestimate production output quantity Overestimate procurement lead times Revised planning within rolling horizon Build up safety stock

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What is Safety Stock Planning?

Use safety stock to safeguard the supply chain against negative effects of uncertain influencing factors like:
Errors in predicting customer demand Disruptions in production Fluctuations in transportation times

Satisfy unexpected demands caused by these factors using an extra amount of material, intermediate products, or end products There is a trade-off between service level and storage costs

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Safety Stock Planning in a Perfect World

The Perfect World Scenario

No Uncertainty Forecast = Observation

Stock

Reorder Point

Reorder Quantity

Time
Replenishment Lead Time

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Safety Stock Planning in the Real World

The Real World Scenario

Uncertainty Forecast Observation

Stock
unexpected high demand unexpected long lead time

Reorder Point

Time Stockout

Replenishment Lead Time

Replenishment Lead Time

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Safety Stock Planning with a Safety Net

The Real World + Safety Net Scenario

Uncertainty Forecast + Safety Stock Observation

Stock
unexpected high demand Reorder Point unexpected long lead time

Safety Stock

Time Stockout

Replenishment Lead Time

Replenishment Lead Time

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Two Main Questions in Safety Stock Planning

For which products and at which locations in the supply chain should safety stock be held?
In SAP SCM SNP, this question is completely left to the planners experience

How much safety stock should be held?

This question can also be left to the planners experience (basic safety stock methods) However, this question can be answered by the system if the necessary input information is available (advanced safety stock methods)

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Inventory Management Strategies with SAP SCM

Basic safety stock calculation methods
Basic methods consider one location and one product at a time Basic safety stock calculation methods are an integral part of the SAP SCM SNP planning run

Advanced safety stock calculation methods

Advanced safety stock calculation methods are decoupled from the SNP planning run Advanced methods consider the network and its structure

Lot size calculations are an integral part of the SAP SCM SNP planning run
Lot size strategies are predefined per location product

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Safety Stock Methods in SAP SCM SNP

1.
Basic Methods

SB Safety stock from location product master SZ Safety days supply from location product master SM Maximum from SB and SZ MB Safety stock (time-based maintenance) MZ Safety days supply (time-based maintenance) MM Maximum from MB and MZ (time-based maintenance) AT AS BT service level and reorder cycle method service level and reorder point method service level and reorder cycle method service level and reorder point method

2. 3. 4. 5. 6. 7.

Advanced Methods

8. 9.

10. BS

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Basic Safety Stock Methods in SAP SCM SNP

Six different basic manual methods

Static or time-based safety stock values Maintained in location product master or in the interactive SNP planning table

Static Safety stock Safety days supply Max {safety stock, safety days supply} SB SZ SM

Time-Based MB MZ MM

Safety stock is built up according to these methods Safety stock values are based on the experience of the planner No support of the system to determine the right figures

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Advanced Safety Stock Methods in SAP SCM SNP

Advanced safety stock planning is model-based
Based on uncertainty and service level Time-dependent For the entire supply chain

Model assumptions
Regular or sporadic demand Backorder case No delay approach Uncertainties are independent from each other

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Parameters for Advanced Safety Stock Methods

Target Days Supply

Service Level
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Definition of Service Levels

Alpha service level

Service level is shortfall event-oriented Number of periods with complete delivery fulfillment/total number of periods Useful if the customer accepts only complete deliveries (all or nothing), or if the fixed costs of subsequent deliveries are high

Beta service level

Service level is shortfall quantity-oriented Quantity delivered in time/total demand Useful if the customer also accepts partial deliveries or the fixed costs of subsequent deliveries are low

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Inventory Strategies According to the Reorder Time

Reorder point strategies
Purchase order decision is stock-dependent Procurement is triggered when stock falls to or is below a predefined stock level (reorder point)

Reorder cycle strategies

Purchase order decision is time-dependent Procurement is triggered regularly at certain points in time (reorder cycles)

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Advanced Safety Stock Planning Methods

Method AT
Alpha service level, reorder cycle strategy Target Days Supply is used as reorder cycle length

Method AS
Alpha service level, reorder point strategy
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Advanced Safety Stock Planning Methods (cont.)

Method BT
Beta service level, reorder cycle strategy Target Days Supply is used as reorder cycle length

Method BS
Beta service level, reorder point strategy Lot size is either equal to Target Days Supply x Forecasted Demand or it is taken from the fixed lot size in the location product master
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Safety Stock Planning Profile

Determination of Forecast Error (Demand/Replenishment Lead Time) Historical data Master data Master data/historical data Determination of Replenishment Lead Time Supply chain Master data Master data/supply chain Demand Type Regular demand Sporadic demand Determine automatically

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Safety Stock Planning

Minimum and maximum value for safety stock

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Safety Stock Planning and SNP Optimization

SNP optimization supports the following methods:

SB SZ MB MZ AT AS BT BS Safety stock from location product master Safety days supply from location product master Safety stock (time-dependent maintenance) Safety days supply (time-dependent maintenance) a service level and reorder cycle method a service level and reorder point method b service level and reorder cycle method b service level and reorder point method

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Consideration of Safety Stock in SNP Optimization

Safety stock is considered as input for the SNP optimization run

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Optimizing Stock Levels with SNP Optimization

Maximum stock level Cost Projected stock Minimum stock level Cost 1 2 3 Buckets

Optimization monitors that actual stock lies between maximum stock level and minimum stock level (= safety stock) Both stock levels can be time-dependent If planned stock is above maximum stock or below safety stock, then penalty cost occurs

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Advanced Safety Stock Planning

Inventory Management and Inventory Optimization Safety Stock Planning in SAP SCM SNP
Inventory Optimization

Inventory Policy Practices

Traditional Approach
50%

Next Generation Approach

40% % of Respondents

30%

20%

10%

0% Inventory policies set using General Rules (e.g., hold 8 weeks of supply for all products). Inventory policies set in Inventory policies set in MRP/DRP or APS System to Multi-Echelon Inventory meet service or cost Optimization System that objectives at one level of the understands demand & leadsupply chain and then time variability across the propagated to other levels. supply chain and assigns policy at each sku-location. Manufacturing-Intensive Companies Inventory policies set by ABCD Categories, determined by product throughput speed (e.g., fast movers).

Distribution-Intensive Companies

Source: Aberdeen Group, 2004; Survey Results of 178 companies

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Inventory Configuration and Policy Vendors

Manufacturing technologies: Capabilities to model deep bills of materials and optimize complex postponement strategies across a multi-tiered network, accounting for supply variances within the network Distribution technologies: Technologies that focus on service levels by both the type of customer and inventory classification by analyzing the right inventory levels based on demand and supply variability within a multi-tiered network

Source: AMR, Redefining the Role SAP 2008 / Advanced Safety Stock Planning Page 32

of Inventory for Demand-Driven Supply Networks, 2005

SAP Enterprise Inventory Optimization with SmartOps

The SAP-SmartOps Enterprise Inventory Optimization solution is used to determine optimal and visible supply chain inventory policies Enterprise Inventory Optimization is a key component of succesful DDSN Integrated Planning and Optimization and Dynamic S&OP processes

Industry Pain Points

High carrying cost of inventory ties up working capital and reduces cash flow Order fill rates and inventory turns are below best-inclass due to uncertain demand and supply events Missing on-time delivery targets is a key factor for customer satisfaction Product proliferation and globalization causes planners and analysts to have less time to manage more supply chains

Solution
xAPP MIPO
Multi-echelon inventory optimization Advanced Demand and Supply Profiling leverages SAP BW/BI Total supply chain view and operational synchronization Implemented in very large scale production environments xApp certification and dynamic SAP integration

Business Benefits
Reduced working capital and improved cash flow 20-40% reduction in Inventory costs 5-10% Improvement in Order Fill Rates 20-30% improvements in Order Lead Times Improved planner and analyst productivity automated, reliable process allows planners to focus on highest value products and customers

Thank you!

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